Method and system of manufacturing a golf club, and a manufactured golf club head

ABSTRACT

A golf club head for playing golf made by a method including providing a powdered metal; and applying a controlled source of energy to the powdered metal layer by layer to form a golf club head, wherein the golf club head is formed as a one-piece golf head having a hollow or partially hollow section and no welds.

BACKGROUND

1. Field of the Invention

The field of invention relates generally to the fitting of golfequipment and the manufacturing of golf equipment and more particularlyto systems and methods designed to improve a golfer's swing andmanufacture golf equipment customized to individual golfer's swing.

2. Related Art

A wide variety of methods have been used to form clubs have been used.Specifically, golf club heads have been forged or cast and then groundor machined, and then polished to achieve desired dimensions andappearances. However, these processes have a number of short comings.

Further, golf club heads have generally been manufactured with averagedimensions based on an average user without any regard to the specificneeds and swing dynamics of specific golfers. This was due to theexpense and/or time required made customizing a head mold to incorporatedesign changes extremely impractical. Thus, to reduce cost and/or savetime, a common mold has been used for the head design regardless of theswing dynamics of users. However, not all golfers are identical and manygolfers may benefit from optimization of club design parameters such aslie angle, loft angle, or other design parameters. Throughpost-manufacturing processing, such as grinding or bending with a vice,may allow some custom fitting of clubs, these processes may have limitedeffectiveness and can create additional problems such as metal fatigueor weakening of the club.

Additionally, existing manufacturing techniques may also requireadditional post processing, such as grinding, due to manufacturingtolerances. Further, existing techniques have limitations in the shapesand dimensions that can be produced.

Therefore, there is a need for golf club heads that can be morecustomized based on a specific user's swing dynamics, as well asmanufacturing methods that can produce a wider variety of shapes withtighter manufacturing tolerances.

SUMMARY

A general purpose of present application is a method of manufacturing agolf club head that can customize more club design parameters to aspecific user's swing dynamics. Various embodiments of the presentapplication may provide a golf club head for playing golf made by amethod including providing a powdered metal; and applying a controlledsource of energy to the powdered metal layer by layer to form a golfclub head, wherein the golf club head is formed as a metallic headhaving a unibody construction without any welds.

Additionally, some embodiments may provide a method of manufacturing agolf club head with less material waste by generating a computer modelof a golf club head, providing a quantity a powdered material, applyinga controlled source of energy to a used portion of the quantity metallayer by layer to form the golf club head, and recapturing an unusedportion of powdered material and saving the unused portion of thequantity of metal powder to be used for other manufacturing.

Other features and advantages of the present application may become morereadily apparent to those of ordinary skill in the art after reviewingthe following detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The structure and operation of the present invention will be understoodfrom a review of the following detailed description and the accompanyingdrawings in which like reference numerals refer to like parts and inwhich:

FIG. 1 is illustrates a flow chart showing a manufacturing process of acustom golf club according to an embodiment of the present application.

FIG. 2A is a diagram illustrating an additive layer manufacturingapparatus using an electron beam, which may be used in a methodaccording to an embodiment of the present application.

FIG. 2B is a diagram illustrating an additive layer manufacturingapparatus using a laser beam, which may be used in a method according toan embodiment of the present application.

FIG. 3 is a sectional diagram illustrating a plurality of portions of aclub that can be manufactured using a method according to an embodimentof the present application.

FIG. 4 is a perspective view illustrating a core of a sandwich orlattice structure that can be manufactured using a method according toan embodiment of the present application.

FIG. 5 is a perspective view illustrating thin-film metal structure thatcan be manufactured according to an embodiment of the presentapplication and applied to a club shaft.

FIG. 6 is a back or internal view illustrating a plurality of club facesmanufactured using a method according to an embodiment of the presentapplication.

FIG. 7 is a sectional view illustrating the plurality of club facesshown in FIG. 6 manufactured using a method according to an embodimentof the present applications.

FIG. 8 illustrates a hollow structure that can be manufactured using amethod according to an embodiment of the present application.

FIG. 9 illustrates a plurality of additional types of supporting latticestructures that can be manufactured using a method according to anembodiment of the present application.

FIG. 10 is a diagram illustrating an example computing environment withan example computing device that could be used to perform a methodaccording to an example implementation of the present application.

DETAILED DESCRIPTION

Certain embodiments disclosed herein provide for a method ofmanufacturing a golf club head. However, although various embodiments ofthe present invention will be described herein, it is understood thatthese embodiments are presented by way of example only, and notlimitation. As such, this detailed description of various alternativeembodiments should not be construed to limit the scope or breadth of thepresent invention as set forth in the appended claims.

FIG. 1 provides a flow chart showing a manufacturing process 100 for acustom golf club according to an embodiment of the present application.In action 105, the user is interviewed to provide initial backgroundinformation to be used to design the custom golf club. Specifically, auser may be asked to fill out a questionnaire regarding the User'splaying statistics. The User's statistics may include, but are notlimited to height, weight, years of playing golf, handicap, putts perround, and #rounds per year. Additionally, the user may also be askedabout the current golf tendencies including: trajectory of shots, swingpath (i.e. hook, slice, etc.) and consistency of shots. Further, theuser's goals regarding distance, ball trajectory, drawing, fading theball, etc.

After the user interview in action 105, the user's current clubs may bemeasured in action 110 to obtain current club design parameters that maybe effecting the User's golf shots. In particular, a variety of currentclub design parameters may be measured including loft, lie, face angle,hosel offset, club length, club weight, club swing weight, shaft weight,shaft flex, grip size, grip weight, and any other parameters as would beapparent to a person of ordinary skill in the art.

After the design parameters of the user's current clubs are measured inaction 105, the user's swing dynamics are analyzed in action 115.Specifically, a user's swing dynamics or Launch parameters with severalclubs may be measured with a launch monitor (such as trackman,foresight, etc.). Using the launch monitor, a variety of swing dynamicsor launch parameters are measured including: head speed, launch angle,backspin, attack angle, ball speed, swing plane angles, club path, spinaxis, horizontal launch angle, tempo, and any other parameters as wouldbe apparent to a person of ordinary skill in the art.

After swing dynamics or launch parameters are measured in action 115,design parameters for the custom clubs are determined in action 120through a fitting process. Specifically, initial fitting clubsdetermined based on the user's height, swing path, and launchconditions. Then final head and club specifications are determined byfitting for:

-   -   Consistency by adjusting or optimizing club length and lie by        dynamic fitting;    -   Distance by adjusting club loft to optimize spin and clubhead        speed by dynamic fitting;    -   Control by adjusting face angle to optimize side spin by dynamic        fitting; and    -   Playability by adjusting shaft, grip, total weight and swing        weight for best feel.

From this fitting, club design parameters for the head and final clubcomponents are determined. Head design specifications are thendetermined from the fitting process to specify the optimal head designand properties. Thus, the club specifications are determined at least inpart from the results of the dynamic fitting process.

After the design parameters are determined in action 120, a computermodel of the club head is generated in action 125. Thus, rather thanmodifying (i.e. by bending, adjusting weight) of existing parts, a clubhead computer model is designed based on the determined designparameters. In some embodiments, the club head id generated by first byselecting a base model (Driver, Fairway Wood, Hybrid, Iron, Wedge,Putter, etc.) from a library of club head models. Then, club designparameters such as volume, loft, lie, face angle, weight, CG properties,inertial properties, shape, offset are entered into the base model whichis then updated based on the user's required specifications.Additionally, in some embodiments, the face thickness and face thicknessgeometry (i.e. back face geometry discussed in greater detail below) maybe adjusted based on the user's head speed and control tendencies. Thecustomized model can be encoded as a CAD file that will be used tomanufacture parts.

After the computer model is generated in action 125, the club head canbe manufactured using additive layer manufacturing techniques that usepowdered metal and high energy beams (such as a laser or electron beam)in action 130.

Electron Beam Apparatus

FIG. 2A is a diagram illustrating an additive layer manufacturingapparatus using an electron beam, which may be used in a methodaccording to an embodiment of the present application. The manufacturingapparatus 200 includes an electron beam column 205 that generates anelectron beam 240 by applying a voltage to a filament 210. The generatedelectron beam 240 passes through a plurality of lenses 215, 220, and 225before entering the vacuum chamber 235 where the club head ismanufactured. The vacuum chamber 235 includes at least one powder hopper245 filled with powdered material 255 that will be melted to form theclub head.

The powdered materials used can be a wide variety of materials andincluding most metals including titanium (Ti), Steel, Aluminum (Al),Titanium aluminum alloys (Titanium Aluminide or TiAl), which generallycannot be cast or welded. More specifically, example materials include,but are not limited to:

-   -   Aluminum Alloys ˜2.86 g/cc—such as AlSi10Mg, AlSi12;    -   Steel Alloys ˜7.8 g/cc—such as Stainless Steel, Hot Worked Steel        (stainless and non stainless);    -   Titanium ˜4.5 g/cc—Pure Ti, TiAl6V4, TiAl6V4 ELI;    -   Silver ˜10.3 g/cc;    -   Gold ˜19.3 g/cc;    -   Tungsten ˜19.2 g/cc;    -   Platinum ˜21.4 g/cc;    -   Nickel Based Alloys such as Inconel;    -   Cobalt-Chrome Alloys such as CoCr;    -   Bronze; and    -   TiAl ˜3.8˜4.0 g/cc (titanium Aluminide).

The manufacturing apparatus 200 may also include a heat shield 230between the electron beam 240 and the powder hopper(s) 245 to preventmelting of the powdered materials 255 prior to being moved into thebuild tank 260. A rake 250 is provided to move powdered material 255into the build tank 250 as needed during the manufacturing.

The electron beam 240 is moved across the surface of the powderedmaterial 255 in the build tank 260 based on the computer model to formthe club head on a layer by layer basis. As each layer is formed, theclub head rests on the start plate 265 and build platform 260. As theclub head is formed, the start plate 265 and a build platform 260 aremoved downward to provide space form successive layers and additionalpowdered material 255.

Though an electron beam 240 is used by the apparatus 200 shown in FIG.2A, the present application is not limited to electron beam basedtechnologies and may include any additive layer manufacturing methodthat uses powdered material and high-energy beams (such as an electronbeam or a laser).

Laser Beam Apparatus

Additionally, FIG. 2B is a diagram illustrating an additive layermanufacturing apparatus 300 using a laser beam, which may be used in amethod according to an embodiment of the present application. Theadditive layer manufacturing apparatus 300 using a laser beam works in asimilar manner to the apparatus 200 discussed above. Specifically, themanufacturing apparatus 300 includes an laser 305 that generates a laserbeam 350. The generated laser beam 350 is directed at a scanner system310 that redirects and controls the laser beam 350 to scan the laserbeam 350 across the surface of a fabrication bed 315 filled withpowdered material 325. Further, adjacent to the fabrication powder bed315, a powder delivery system 320 is provided to add additional powdermaterial 325 to the fabrication bed 315 as needed. The powder deliversystem 320 includes a powder tank 355 filled with powdered material 325,a powder deliver piston 330 that moves upward to push powdered material325 upward and a roller 335 that directs powdered material to thefabrication powder bed 315.

The scanner system 310 controls the laser beam 350 to move the laseracross the surface of the fabrication bed 315 based on the computermodel to form the object being fabricated 340, layer by layer. Assuccessive layers of the object 340 are formed, a fabrication piston 345is retracted downward to gradually lower the object 340 and allowpowdered material 325 to flow over the top of the object 340 so thatsuccessive layers can be formed.

As with the electron beam apparatus 200 discussed above, a wide varietyof powdered materials can be used in the laser beam additive layermanufacturing apparatus 300, including most metals including titanium(Ti), Steel, Aluminum (Al), Titanium aluminum alloys (Titanium Aluminideor TiAl), which generally cannot be cast or welded. Thus, the examplematerials include the same materials discussed above with respect to theelectron beam apparatus 200

Example Structures

These additive layer manufacturing techniques allow manufacturing ofsurface features having a minimum thickness of Surfaces equal to 300microns (um). Further, structures of mesh or lattice structures such asthose shown in FIGS. 3, 4, 8 and 9 discussed below may have a minimumthickness equal to 150 microns (um).

In some embodiments, the golf head may be manufactured to have a onepiece (or unibody) construction, with the face and body (crown, skirt,sole) being formed as a one-piece golf head having hollow or partiallyhollow sections without a need to weld components together. In someembodiments, a small exit hole may be used to remove powder trappedwithin hollow areas of the head, but the exit hole can be drilled afterthe head is manufactured.

Using the additive layer manufacturing techniques, any type of golf clubhead could be theoretically manufactured based on a generated computermodel without a need to retool, producing a variety of clubs faster thanmethods previously used, such as casting, stamping or forging.Additionally, in some embodiments, using additive layer manufacturingtechniques may allow a reduction in waste material because 95˜98% ofpowder can be reclaimed and used to make more parts. Conversely, forgingand casting processes typically produce significant amounts of wastematerials.

Additionally, additive layer manufacturing techniques may not requirewelding of multiple pieces together because clubs can have unibodyconstruction to form a one-piece golf head having a hollow and/ornon-hollow sections with no welds. Further, as would be apparent to aperson of ordinary skill in the art, if welding is not required, theoccurrence of heat affected zones that degrade material properties maybe reduced.

The additive layer manufacturing process eliminates thickness and weightvariations often caused by grinding to remove material, thermalexpansions and shrinkage caused by the lost wax casting process, andinconsistencies and tool wear with conventional tooling processes.

As the additive layer manufacturing processes do not require grinding,which may cause varying thickness or weak spots, tooling, or welding,which may cause thermal expansion or shrinkage, tighter tolerances canbe held. These tighter tolerances may also be a reduced need to“re-work” or “repair” out of spec. parts, which can produce a costsavings.

Further, additive layer manufacturing processes may not suffer Flowconstraints that casting may experience. Further, additive layermanufacturing processes have higher porosity compared to casting (99.5%dense) and may produce more durable part with thinner structures

Further, additive layer manufacturing techniques may allow themanufacturing of complex geometries not achievable with casting,machining, or forging techniques typically used. FIGS. 3-9 illustrate asampling of the structures that can be manufactured using additive layermanufacturing techniques.

For example, internal 3D geometries that can not otherwise bemanufactured, such as those shown in embodiments (a)-(i) of FIG. 3, maybe manufactured. Further, undercuts such as those shown in embodiment(j) of FIG. 3 may be formed without the need for special tooling.Further, separate pockets and slots, typically too difficult to cast ormachine, such as those shown in embodiments (k) and (l), can bemanufactured using additive layer manufacturing techniques. Thus, ironbodies/soles can be made with undercuts/complex geometries can bemanufactured.

Further, 3D lattice/core geometries having a thin skin of metal oneither side (1 side), both sides (sandwich), or without a skin on eitherside (open core), such as those shown in FIG. 4 may also bemanufactured. Also, a thin non-metallic skin can also be bonded orjoined to the core. These 3D lattice/core geometries are discussed inmore detail with respect to FIGS. 8 and 9 below.

Additionally, face inserts have complex variations in face thickness andface geometry, such as those shown in FIGS. 6 and 7 may be manufactured.Specifically, as shown in FIGS. 6 and 7, face inserts having multipleregions of different discrete thicknesses can be manufactured with thethickest regions being located at different portions of the club facedepending on design needs. Further, face plates may have complexinterior geometries having lightweight cores or lattice structuresbetween skins as shown in FIG. 7 may be manufactured. Since nowelding/grinding is necessary, a minimum thickness necessary to have amaximum Coefficient of Restitution can be manufactured, and the insertsstill having sufficient durability.

Further, these face inserts can be manufactured to be have complexinternal geometries using additive layer manufacturing techniques andthen welded to bodies formed using conventional methods such as casting,stamping, or forging. These face inserts can be custom made for based onthe player's striking tendencies (i.e. to have max thickness where theplayer consistently impacts striking face and with thicknesses reducingto maximize the Coefficient of Restitution.

Further, the additive layer manufacturing techniques is not limited tomanufacturing the club head and may also be used to manufacture thinmetal foils. These thin metal foils may be manufactured and wrappedaround on a composite or metal shaft substrate to change or customizethe performance characteristics and/or add cosmetic effects to a golfshaft. FIG. 5 a shows an example embodiment of a thin-metal foil 505 andFIG. 5 a shows the thin-metal foil 505 wrapped around a shaft 510.Alternative, a Lightweight lattice structure can be inserted into thehollow inner diameter of the shaft to change the stiffness/performanceof the shaft.

As discussed above, complex 3D geometries or 3D lattices can bemanufactured as a weight efficient support structure or as a lightweightsupporting core for thin walls. FIG. 8 illustrates an enlarged view ofan embodiment having thin walls 805, 810 with a plurality of supportinglattices 815 formed between the thin walls 805, 810. Further, FIG. 9illustrates a plurality of types of 3D lattice structures that can bemanufactured using additive layer manufacturing techniques. Theseinclude pyramidal lattices (a), tetrahedral lattices (b), 3D-Kagomelattices (c), diamond textile lattices (d), diamond collinear lattices(e), and A square collinear lattices (f). These structural shapes may toincrease strength/stiffness, lower weight, and change or optimize the“feel” of the club. The lattice geometries shown in the presentapplication are merely examples and embodiments of the presentapplication are not limited to these shapes. Further, the latticegeometries may also include a 3D mesh designed and optimized to providethe head characteristics desired based on the user's needs.

These “lattice” geometries manufactured using additive layermanufacturing techniques can be applied to any part of a golf club head,including the sole, crown, skirt, etc. and is not particularly limitedto only the hitting face. These lattices can also provide an internalsupport structure to join two sections (for example can be a bridgebetween the crown and the sole to provide stiffness). Further, thelattice geometries can be manufactured separately or integrated into 1piece heads.

Additive layer manufacturing can also allow the development of any otherdetails or shapes that have previously been too fine to be cast ormachined, such as springs and teeth of a snap clip allowing components(weights) to be attached to an exterior of a club head. The embodimentsshown and discussed above are not intended to be limited and are merelyprovided as examples.

Additionally, as additive layer manufactured golf club componentsrequire minimal post manufacturing finishing, that may reducemanufacturing cost or time. Further, additive layer manufacturingdiscussed above can also allow the “printing” of a surface finish orengineered texture on the face or any exterior surface to influencespin, aerodynamics, or acoustics (sound).

After the heads and other club components are manufactured and finishedin action 130 of the FIG. 1, the heads are assembled to the requiredshafts and grips to achieve the club specifications (length, weight,flex, etc.) determined as optimal during the fitting process in action135. Thus, a final golf club is supplied that is made specifically forthe individual golfer based on his unique player characteristics, andhis unique requirements to give optimal performance. The properties andparameters of the head components are determined and manufactured to becustomized to the individual to a much greater extent that was previousavailable.

Example Computing Device And Environment

FIG. 10 shows an example computing environment with an example computingdevice suitable for implementing at least one example implementation.Computing device 1005 in computing environment 1000 can include one ormore processing units, cores, or processors 1010, memory 1015 (e.g., RAMor ROM), internal storage 1020 (e.g., magnetic, optical, or solid statestorage), and I/O interface 1025, all of which can be coupled on acommunication mechanism or bus 1030 for communicating information.

Computing device 1005 can be communicatively coupled to input/userinterface 1035 and output device/interface 1040. Either one or both ofinput/user interface 1035 and output device/interface 1040 can be awired or wireless interface and can be detachable. Input/user interface1035 may include any device, component, sensor, or interface, physicalor virtual that can be used to provide input (e.g., keyboard, apointing/cursor control, microphone, camera, braille, motion sensor,optical reader, or the like). Output device/interface 1040 may include adisplay, monitor, printer, speaker, braille, or the like. In someexample implementations, input/user interface 1035 and outputdevice/interface 1040 can be embedded with or physically coupled tocomputing device 1005 (e.g., a mobile computing device with buttons ortouch-screen input/user interface and an output or printing display, ora television).

Computing device 1005 can be communicatively coupled to external storage1045 and network 1050 for communicating with any number of networkedcomponents, devices, and systems, including one or more computingdevices of the same or different configuration. Computing device 1005 orany connected computing device can be functioning as, providing servicesof, or referred to as a server, client, thin server, general machine,special-purpose machine, or by other labels.

I/O interface 1025 can include, but is not limited to, wired and/orwireless interfaces using any communication or I/O protocols orstandards (e.g., Ethernet, 802.11x, Universal System Bus, WiMax, modem,a cellular network protocol, and the like) for communicating informationto and/or from at least all the connected components, devices, andnetworks in computing environment 1000. Network 1050 can be any networkor combination of networks (e.g., the Internet, local area network, widearea network, a telephonic network, a cellular network, satellitenetwork, and the like).

Computing device 1005 can use and/or communicate using computer-usableor computer-readable media, including transitory media andnon-transitory media. Transitory media include transmission media (e.g.,metal cables, fiber optics), signals, carrier waves, and the like.Non-transitory media include magnetic media (e.g., disks and tapes),optical media (e.g., CD ROM, digital video disks, Blu-ray disks), solidstate media (e.g., RAM, ROM, flash memory, solid-state storage), andother non-volatile storage or memory.

Computing device 1005 can be used to implement techniques, methods,applications, processes, or computer-executable instructions toimplement at least one implementation (e.g., a describedimplementation). Computer-executable instructions can be retrieved fromtransitory media, and stored on and retrieved from non-transitory media.The executable instructions can be originated from one or more of anyprogramming, scripting, and machine languages (e.g., C, C++, C#, Java,Visual Basic, Python, Perl, JavaScript, and others).

Processor(s) 1010 can execute under any operating system (OS) (notshown), in a native or virtual environment. To implement a describedimplementation, one or more applications can be deployed that includelogic unit 1060, application programming interface (API) unit 1065,input unit 1070, output unit 1075, design parameter determining unit1080, club head modeling unit 1085, manufacturing controller 1090, andinter-unit communication mechanism 1095 for the different units tocommunicate with each other, with the OS, and with other applications(not shown). For example, design parameter determining unit 1080, clubhead modeling unit 1085, action unit 1090, along with one or more otherunits, may implement one or more processes shown in FIG. 1. In someexample implementations, design parameter determining unit 1080 mayinclude two or more separate units. The described units and elements canbe varied in design, function, configuration, or implementation and arenot limited to the descriptions provided.

In some example implementations, when information or an executioninstruction is received by API unit 1065, it may be communicated to oneor more other units (e.g., logic unit 1060, input unit 1070, output unit1075, design parameter determining unit 1080, club head modeling unit1085, manufacturing controller 1090). For example, club head modelingunit 1085 may generate a computer model of a club head based on designparameters determined by the design parameter determining unit 1080based on received user's swing dynamics.

The design parameter determining unit 1080 may use the inter-unitcommunication mechanism 1095 to receive a user's swing dynamics inputvia the input unit 1070. Further, the design parameter determining unit1080 may determine club design parameters based on the input user swingdynamics and may communicate the club design parameters to the club headmodeling unit 1085. The club head modeling unit 1085 may generatecomputer model of a golf club head based on the determined club designparameters and communicate the computer model to the manufacturingcontroller 1090. The manufacturing controller 1090 may use the generatedmodel to control additive layer manufacturing equipment to manufacture agolf club head based on the received model.

In some examples, logic unit 1060 may be configured to control theinformation flow among the units and direct the services provided by APIunit 1065, input unit 1070, output unit 1075, the design parameterdetermining unit 1080, club head modeling unit 1085, manufacturingcontroller 1090 in order to implement an implementation described above.For example, the flow of one or more processes or implementations may becontrolled by logic unit 1060 alone or in conjunction with API unit1065.

Although a few example implementations have been shown and described,these example implementations are provided to convey the subject matterdescribed herein to people who are familiar with this field. It shouldbe understood that the subject matter described herein may be embodiedin various forms without being limited to the described exampleimplementations. The subject matter described herein can be practicedwithout those specifically defined or described matters or with other ordifferent elements or matters not described. It will be appreciated bythose familiar with this field that changes may be made in these exampleimplementations without departing from the subject matter describedherein as defined in the appended claims and their equivalents.

The above description of the disclosed embodiments is provided to enableany person skilled in the art to make or use the invention. Variousmodifications to these embodiments will be readily apparent to thoseskilled in the art, and the generic principles described herein can beapplied to other embodiments without departing from the spirit or scopeof the invention. Thus, it is to be understood that the description anddrawings presented herein represent a presently preferred embodiment ofthe invention and are therefore representative of the subject matterwhich is broadly contemplated by the present invention. It is furtherunderstood that the scope of the present invention fully encompassesother embodiments that may become obvious to those skilled in the artand that the scope of the present invention is accordingly not limited.

1. A golf club head for playing golf made by a method comprising:Providing a powdered metal; and Applying a controlled source of energyto the powdered metal layer by layer to form a golf club head, Whereinthe golf club head is formed as a one-piece golf head having a hollow orpartially hollow section and no welds.
 2. The golf club head of claim 1,wherein the applied controlled source of energy is controlled based on acomputer model of a golf club head generated based on club parametersdetermined based on a specific user's swing dynamics.
 3. The golf clubhead of claim 2, wherein the computer model is generated based on atleast one of a user's golf club swing speed, golf ball launch spin rate,and golf ball launch angle.
 4. The golf club head of claim 2, whereinthe determined club parameters include at least one of: Hosel offset;Club head volume; Club face height; Club face length; Placement ofvisual alignment aids; Club head Sole curvature; Club head sole bounce;and Club head sole grid.
 5. The golf club head of claim 2, wherein thedetermined club parameters include at least one of: Club head facethickness; Club head face (hitting surface) center of gravity; and Clubhead face thickness geometry.
 6. The golf club head of claim 2, whereinthe computer model of the golf club head is generated by: Selecting abase model of a golf club head from a plurality of predefine club headmodels; Modifying the base model based on the determined club designparameters
 7. The golf club head of claim 6, wherein the base modelcomprises at a model of at least one of a driver model, fairway woodmodel; hybrid model; iron model; wedge model and putter model.
 8. Thegolf club head of claim 6, wherein the modifying the base modelcomprises changing at least one of: Hosel offset; Club head volume; Clubface height; Club face length; Placement of visual alignment aids; Clubhead Sole curvature; Club head sole bounce; and Club head sole grid ofthe base model.
 9. The golf club head of claim 1, wherein the golf clubhead comprises a hollow golf club head having a supporting latticeformed within the hollow golf club head.
 10. The golf club head of claim9, wherein supporting lattice is at least one of: A pyramidal lattice; Atetrahedral lattice; A 3D-Kagome lattice; A diamond textile lattice; Adiamond collinear lattice; and A square collinear lattice.
 11. The golfclub head of claim 1, wherein the golf club head comprises a club facehaving an asymmetrical cross-section with thickness variations.
 12. Thegolf club head of claim 1, wherein the golf club head comprises faceinserts having non-uniform cross-sections.
 13. The golf club head ofclaim 12, wherein the inserts are hollow inserts having an internalsupporting lattice.
 14. The golf club head of claim 13, wherein thesupporting lattice is at least one of: A pyramidal lattice; Atetrahedral lattice; A 3D-Kagome lattice; A diamond textile lattice; Adiamond collinear lattice; and A square collinear lattice.
 15. The golfclub head of claim 1, further comprising a hollow portion having atleast one internal rib formed therein.
 16. The golf club head of claim1, further comprising an engineered texture or design formed in at leastone portion thereof.
 17. The golf club head of claim 1, furthercomprising at least one attachment feature.
 18. The golf club head ofclaim 1, wherein the at least one attachment feature is selected from atleast one of: a clip; a snap; a pocket; a threaded surface; and a slot.19. A method of manufacturing a golf club head with less material waste,the method comprising: generating a computer model of a golf club head;providing a quantity a powdered material; applying a controlled sourceof energy to a used portion of the quantity metal layer by layer to formthe golf club head; and recapturing an unused portion of powderedmaterial and saving the unused portion of the quantity of metal powderto be used for other manufacturing.
 20. The method of claim 19, whereinthe golf club head is a hollow golf club head and wherein recapturing anunused portion of powdered material comprises forming a hole through awall of the hollow golf club head; and drawing unused powder materialfrom the hollow interior of the golf club head through the hole.